Apparatus for and method of making boiler headers



' J. J: CAIN Aug. 18, 1931.

APPARATUS FOR AND METHOD OF MAKING BplLER HEADERS Filed April 6, 1928 4 SheetsSheet l ATTORNEY Aug. 18,1931. AIN 1,819,636

APPARATUS FOR AND METHOD OF MAKING BOILER HEADERS Filed April 6. 1928 ASheets-Sheet 2 .1. J. CAIN Aug. 18, 1931.

APPARATUS FOR AND METHOD OF MAKING BOILER HEADERS Filed April 6, 1928 4Sheets-Sheet 3 Aug. J. J. CAIN APPARATUS FOR AND METHOD OF MAKING BOILER HEADERS Filed April 6 1928 4 Sheets-Sheet 4 Patented Aug. 18,- 1931 stra n srnres J'OHLN J. CAIN, 0F BAYONNE, NEW vJERSEY Application filed April :6,

This invention relates to improvements in apparatus for and method of making'boiler headers.

The principal object of'the in'vention is the provision of such an: apparatus whereby boiler headers may be made by aneansofdie and mandrel, and in which the metal io-fthe header will be uniformly bent and pressed from one endto the other, with the eliminaas tion of'weak or uneven spotsor places and without breakage or cracking or tearingz Adnrthe'nobject of this invention is} the provision ofsuch an apparatus in which' the dies by which the header is shaped are 15 pressed gradually and progressively from one end to the other of the metal, in *contradistinction to complete andinstantaneous pressure over theentire extent of the'metal at one time.

A further object of this inventionresides in the method ofinakin-g a boiler header by which the same isshaped from a blank-or tube'of metal by die pres-ure beginning at one end and applied progressively throughout the length of the metal to theother end.

A further object of this inventionres-ides in the making of a boiler header having undulatory sides staggered with reference to each other and having inclined seats provided on 'theto-p thereof by shaping a blank or tube by die pressure of side dies and-a top die, the pressure beginningat one end and then applied progressively throughout the length of theblank to the-other end.

A further object of this invention is the provision of an apparatus of-the character described in which side dies are mounted so as to be actuated and have a scissors-like action in engaging thesides of a blank to be formed into the completed head'erywhereby the blank will be engaged andpressed initially at one'end and progressively from that end throughout its length.

A further object of this inventionis the provision of afknockdown form of mandrel which may be readily, placed in position within the blank and-removed therefrom when. the shaping operation is completed.

To the accomplishment of the foregoing and such other-objects as-may hereinafter 1928. SeriaI'tNo. 2883043.

appear, this'invention consists in :the construction; combination and arrangementgof :partsand the method hereinafter described an'c t'then sought fto' be defined in thewap pended vclainis, -reference being had ito the 1.555 acoompay nin g. drawings, forming a .part hereof and which show for ith6-"-P111POS6'O1E illustrative adisolosure wone embodiment of my invention in Fan apparatus fidELPtedTtO practiceltheprocess, it being expressly under- 50 stood, however, that variouschanges may be made in practice within' the .scopeof'the claims Without :digressing' :fronr my inventive idea. Y

Inflthe drawings' s Figure 1 represents :an -end relevation, parts-being shown in section, of one form of apparatus constructed to embody my -invention and to be operated according to any --1nethod.

Figure 2 is a vertical longitudinal section taken substantially O11llI182-'2-OfFlg1l-18 1.

Figure :3 is' a tOp'ip'lan view of the apparatus shown in Figure 2; parts :being broken away to facilitate tl1e=disclosure-.

Figure 4 is a side elevationof'the "view shown :in Figure 3.

Figuret is a detailed perspective ofone of the'side die members; .v

Figure 6 is a bottom plan View eofthe top-die member:

Figure 7 is a seetiolrt-aken substantially on line 77 of Figure 2,*showing rthe top {(119 *member and theaneth'od of securing and operating the same. 85

FigureS is :a top plan view of a completed header, parts being-broken away 'to' show the mandrel in position.

Figure 9 is a cross section takensu-bsta'm tial ly online 9 9 of Figure 8.

Figure 10 is a seotion of half of a header and the enclosed iman'drel taken on line 1010 ofFigureS.

Figure '11 is'a perspective view :pleted header-of one formz- He'retofore headers for boilers have been made by: means of die-shaping operations an which the entire die or dies are brought into contact with the blank or tube and the e tire lengthof the blank or tube shaped at 10c one time. Because of this operation the metal of the blank or tube must give in certain places more than in others, which results in the formation of headers of uneven thickness of material, and also results in breakage of a large number of blanks and cracking of the headers.

The purpose of my apparatus and method is to overcome these disadvantages and to enable the production of headers from a blank or tube of metal with a minimum amount of breakage and cracking, and with the thickness of the metal uniform throughout the header in its entirety. To this end the apparatus is generally in the form of a pair of die-holding members pivoted at one end and then moved gradually into engagement with the blank or tube having a mandrel therein. Pressure is therefore applied to one end of theblank or tube first and gradually, and then gradually and progressively to the remainder of the tube or blank until the end is reached. At the completion of the pressing movement of the die-holding members, the entire blank or tube will beengaged by the dies and the shaping operation completed. In addition to the side dies being constructed and arranged in this manner, the top die is similarly arranged and operated, that is, so that it has initial engagement with one portion of the tube or blank and progressive engage ment with the remainder of the tube or blank, until the entire top surface thereof is engaged and pressed into its final formation.

Referring now to the drawings in which one embodiment of my apparatus is disclosed, the numeral 1 designates the base of the frame of the apparatus. This fbase forms a support for the various parts thereof. Centrally thereof is arranged and posi tioned an anvil or work-supporting member 2 which is of general T-shape, having the work-supporting head portion 3. The work supported on said head portion 3 is adapted to be operated upon by side dies and a top die. The side dies are designated generally by the reference character a having the forming part 5 and the base part 6, by means of which they are secured in a recess 7 in the holding and operating members 8. These holding and operating members 8 are of substantial and weighty construction, having the broad base portion 9 adapted to rest upon the base member 1 and to extend beneath the work-holding head 3 when in contact with the work and during the pressing operation. These two holding and operating members 8 for the side dies are pivoted to the rear end of the base 1 as at 10, being provided with the offset and reduced apertured bosses 11 and 12 for that purpose.

The top. forming die is designated generally by the reference character 13 and is positioned and held in the top member 14L, which extends toward the rear of the apparatus and is horizontally pivoted as at 15, being provided with the loop portion 16 to extend over and escape the pivot 10 and the apertured bosses 11 and 12.

In the apparatus shown, pressure is applied by means of manually-operated screw constructions. It is to be expressly understood that this showing is illustrative only and that pressure may be applied by hydraulic means, fluid pressure of various kinds or, in fact, any practical way. In order to permit the application of pressure by screws I provide yoke member 17 which has its free ends 18 attached at the sides of the base member 1 and has vertical side portions 19 and the horizontal top portion 20. A screwmember 21 having the operating handle. or wheel 22 is screw-threaded into each of the side members 19 of the yoke and has a rotatable engagement with the side the holding and operating members, as at 23, whereby a rotation of the handle or wheel 22 results in movement of these members 8. A screw member 24 extends vertically in screwthreaded engagement with the top member 20 of the yoke and is provided with a handle or wheel 25, and has a rotatable engagement as at 26 (see Figure 7 with the top die-holding and operating member 14, so that when the handle or wheel 25 is rotated, the top die 13 will be moved.

Before proceeding to a description of the blank and the article made and the dies' themselves, attention is particularly directed to the fact that the two side die-holding and operating members are pivoted at the rear of the apparatus, so that when pressure is applied to these members 8 by means of the screw members or equivalent means previously referred to, the side dies will be moved in gradually into engagement with the work, the first engagement taking place nearest the rear end of the machine, that is looking at Figure 3. Further application of pressure results in progressive engagement of the dies with the work, that is, progressive from the rear end toward the front end, and when the dies are forced into parallel relation with each other, which is their final position, the work, that is the blank or tube, will be engaged entirely along its length and, therefore, completely shaped by the side dies. It is also to be noted that the top die holding and operating member is pivoted at the rear and that the first engagement of the top die with the work will be at the rear and further application of pressure thereto will result in progressive application of die pressure to the work, that is the blank or tube, until the die is parallel to the base and the die-shaping operation complete with the top die in engagement with the work throughout-{its entire extent.- This results in the ,be subjected to tgraduallyincreasing ;}PI'ES- sure progressivelyirom the rear 11in toward the frontend, whereby it will give andbe shaped without the abrupt changes due to the instantaneous application ot pressure throughout its entire-extent, as -in Ithe old apparatus and method.

One form of 'side-dieis {shown in" Figure 5 of the-drawing and inthatffor-m the forming part is-shaped SOftSxtO forma series of-undulations in the side of the blank, these :un-

.dulat ions being arranged at an angle' or obliquely The undulations on opposite sides ofthe completed header are arranged to complement each other so th-at thecompleted header is of substantiallyconstant width throughoutnit -entire length, being composed of alternate protuberances 27 .and hollows or indentations 28 on one side which are located opposite the complementary hol- .lows or. indentations 29 and .protuberances 30 011 Ltheother sideof the header (seeFigure 8). This construction is desijgned for use in anoifset arrangement of-hoilertubes, as is wellunderstood.

One form of top :die is formed as illustrated in Figure-6, as having a general wavy or undulatory shape, indicated at 31, that is lookingat the sides, and havinga serrated appearance-formed by a plurality oi inclines .32 leading ,to shoulders 33 formed 'by more abrupt inclines These parts are ofiset as indicated .in Figure 6 so as :to correspond to the offset formation caused "by the 'side dies, as 'above described. In-other words, the top die-provides a series {of inclined surfacesor faces 32 terminated by rather abrupt shoulders 33, which are offset to correspond to the'simila'r undulatory constructiono'f the header as formed by the side dies.

In the forming operation, it is necessary to utilize a mandrel construction and this mandrel construction is illustrated in Figures 8,9 and 10 .Itincludes .the bottom member 340i .sufiicientlength to fit entirely through the blank or {tube and the :top member 35 of the same length. The meeting edges of-these two members 34 and 35am on an anglesoas-to complement each other in having a wedgelike operationior insertion and removal. The top member 35 is formed with ya plurality of comparatively gradual inclines or slopes 36 terminated by .the abrupt inclines or shoulders 37 corresponding in shape to the top'die with its inclines :32 and shoulders 33 and to the completed header, as shown in Figure 11. In

=the sides of which are formed in --undulatory or wavy shape, ;asuat-39, corresponding to and complementary to-the-undulatory shape of the side dies. The two parts of this 7 divided mandrel :member 38 have beveled meeting edgesaO'and reduced-portions 41 fitting :in and held in place byqthe main mandrel members 64k and 35,--as-clearly shown in Figure 10. This side mandrel construction is arranged so thataa protuberance is formed :inone side and directly opposite appears a hollow or indentation to correspond to the arrangement of I the side die members previously described. It istherefore seen that this mandrel as a whole is of knockdown construction and readily placed in position and removed from the completed header.

For removal'it is onlyanecessary to take out oneof the-members 34 and35 and then the parts will :drop so that theoth'er members or parts of the mandrel can be readily removed. In view aOfJtl l'fi undulatory shape of the completed header and also the manheader, in order zthat' they may be withdrawn. The undulatory side pieces of the mandrel 38, of course,:whe1rin position extend :the full width of :the bore of the completed header. However, they are much less in height than theheight of the bore through the headerwbecause it is only necessary to resist pressure .over a comparatively short distance. These side mandrel members, therefore, resist pressure suiiiciently' to enablekthe'complete header to be shaped as a whole. Of course, making the side mandrel-'members thinner is'gan important factor inthe removaloi themandrel as a whole.

Thedcharacter of blank used is not-oi material importance as long asit is hollow.

Of course, the most usual form would be cylindricalor circular in cross-section, but this apparatus and method are' readily applicable @to other forms of blanks.

It is to be particularly noted that the arrangement of the die-holding members .or arms, :that is the pivotal construction of the same, is such as to cause the dies to initial- 1y engage the blank at one end and when these members are further actuated, the engagement will be progressive throughout the length of the blank to the other end, during which time the pressure upon the endfirst engaged willbe increased and also the increased pressure willtbe applied progressively 'to theremainder of the blank. This is due to the scissors-likeaction or operation of the dies and diehol'ding members. .Vhen =the'=-shapi1rg operation is complete, the dies for the sides ofthe header will be positioned in parallel relation and the top die will, in some cases'at least, be in parallel relation diameter heretofore referred to. 'clined faces or surfaces 42 are slightly stagto the work support. Of course, if it is desired to form headers having inclined sides and top, or having these parts of other relative format-ions, this can be taken care of by changing the dies and the position of the dies in the holding and actuating arms therefor. 1

Referring particularly to Figure 11 it is to be noted that the header itself in one form has its top formed with a plurality of inclined faces or surfaces 12 terminated by more abruptly inclined shoulders 43 and that the sides of this header are undulated as indicated at ll and 15, the undulations Jeing arranged to complement each other so that the head-er has the uniform internal The ingered or offset with relation to each other and are adapted to be bored as indicated at 46 to receive the boiler tubes, which will eX- tend at an angle relative to the header.

Of course, it is obvious that other forms of headers may be made in which the faces or seats for the boiler tubes will be straight or inclined differently and in which the side undulations may be straight or vertical with respect to the header as a whole, or inclined differently from those shown in the drawings. Furthermore, a header may be formed 111 which the top thereof is straight and flat and parallel with the bottom, in which event the side undulations are arranged vertically with respect to the header as a whole.

A very important advantage obtained by.

the use of the apparatus disclosed and-in accordance with the method described is that the material of the blank is engaged slightly at the initial stage of the shaping opera tion, and as the pressure continues, the engagement of the dies with the blank will increase toward the other end and the part that the blank already engaged will be subjected to a greater shaping movement. Furthermore. it is not until the shaping dies reach their ultimate or final position that the pressing or shaping operation is complete, and as the application of pressure begins at one end and this is initiated gradually toward the other end and the shaping movement of the blank begins at one end and is carriedprogressively and gradually to the other end, the metal of the blank will be able to accommodate itself to the shaping operation so as to avoid undue thinness and unevenness where the shaping ance. straight.

lVhat I claim is-:

l. The method of forming a boiler header including the operation of die-shaping a stationary hollow blank with a mandrel therein by pressure of a plurality of dies applied progressively from one end of the blank to the other. e

2. The method of forming a boiler header including the operation of die-shaping a stationary hollow blank with amandrel therein by pressure of a die on each side applied progressively from one end of the blank to the other.

3. The method of forming a boiler header including the operation of die-shaping a stationary hollow blank with a mandrel there in by pressure of a die on each side applied progressively from one end of the blank to the other and of a top die applied progressivelyv from one end of the blank to the other.

4. The method of forming a boiler header including the operation of die-shaping a stationary hollow blank with a mandrel therein by pressure of a die on each side applied progressively from one end of the blank to the other, until the sides of the completely formed header are parallel.

5. The method of forming a boiler header including die-shaping a hollow blank with mandrel therein by the scissors-like action of a pair of side dies engaging and pressing the sides of the blank progressively from one end thereof to the other.

6. The method of forming a boiler header including die-shaping a hollow blank with a mandrel therein by the scissors-like action of a pair of side dies engaging and pressing the sides of the blank progressively from one end thereof to the other, until the sides of the header are parallel to each other.

7. The method of forming a boiler header including die-shaping a hollow blank with a mandrel therein by the scissors-like action of a pair of side dies engaging and pressing the sides of the blank progressively from one end thereof to the other, to form undulatory side faces arranged in staggered relation to complement each other.

8. The method of forming a boiler header including die-shaping a hollow blank with The surfaces '42 are substantially a mandrel therein by the scissors-like action in said arms, and means for actuating said arms, and

arms and dies to engage and shape the sides 10. An apparatus for forming boiler headerg-including a mandrel adapted tobe inserted' in a blank, a -pai-r ofholdingand oper-- ating arms pivotedatone-end, dies for shaping the sides of saidblanksprovided in said blank progressively-from: one endto the other; the dies being parallel when the shaping operation is completed so' that the-sid'es of the blank are parallel when completed.

11. An apparatus for forming boiler headers, including a mandrel adaptedto be insertediin' a blank, a pair of holding and operating arinspivoted at oneend, dies for shaping the-sides ofsa-id blank provided in said arms, and means for actuating said arms and dies-to-engage'and shape the sides:

of said blank progressively from one end to the other, said dies having undulatory v pressing vi'ded'in said arms, means for actuating said arms and dies to engage and shape the sides of said blank progressively from one end to the other, and atop arm pivoted to the apparatus, a top die provided t'lierein, and-means for applying pressureto the top arm and die so asto-engage the top portion of the blank progressively from one end to: the other.

'13. Anapparatus for formingboiler headers, includ-ing a mandrel adaptedto' be insorted in a blank, a pairv of holding and 45 operating arms pillotedfit'one dies for shaping the sides of saidblank provided in said arms, .means for actuating said arms and dies to engage said blankprogressively from one endto the other, a top arm pivoted tothe'apparatus, a top die provided therein, and means for applying-pressure to t'he top arm and die so as to engage the top portion of the blank progressively from one-endltothe -other,the top die being parallelwith the base of the apparatus when the" shaping operation is completed so that the general plane. ofithe top ofithe header is parallel witlr the general .plane of the bottom of the header.

14. An apparatus for forming boiler headers, including a base, a work support on said base, a pair of. side holding and operating armspivotedto said base at one end, 7 dies for shaping thesides of a blank providmeansfor actuating'said arms-andv dies-to engage-and shape the sides-ofsaid" faces arranged in staggeredrela- I 'tion to complement each other 111' formingand' shape the sides of ed in said arms, a top arm pivoted near the same end of said apparatus, and atop die provided in said top arm, amandrel adapted in a blank held on the Work to be inserted support, and means for applying pressure tosaid side arms and said top arms so that the side dies and top dies engage the-blank beginning at one end andpressureis applied pro blank to the otherend.

15. An apparatus forforming boiler headers, including a base, a work support on said base, a pair of side holding and operating armspivoted tosaid base at one end, dies for shaping the sides of a blank provided in said arms, a top arm pivoted near the same end of said apparatus,-and a top die provided in said top arm, a mandrel adapted to be inserted I in a blank held on the Work e support, and means;- for applyingpressure to said side arms and said top arin so that thesidei'dies and! top dieeiigage the blank beginning. at one endand pressure is applied progressively throughout the length of the blank to the other end, saidsidedies being of undulatory conformation and staggered with reference to each other so that the completed header is formed with undulationson each side staggered withrefei'ence to the undulations on the other side.

16. 111 an apparatus for forming boiler headers, including a support for the work, a plurality :of: die holding and operating arms provided with. dies, and means for forcing said armsnnd dies against the work, a mandrel adapted tobe inserted: within the Work which is in the form of a hollow blank,

said mandrel including a pair of longitudinally extending. members and a pair of longitudinally and laterally extendingmembers positioned and held therebetween, said laterally extending members ,havingtheir outsi'de'edges. formed with undulations, the undulations of one member" being offset or staggered with reference to'the undulations of the other member and corresponding to theshape of certain'of the dies, said top longitudinal member of the mandrel being 1 formed with a plurality of inclined surfaces terminated by. shoulders formed by sharply ressivelyf throughout the length of the inclined surfaces corresponding to the simi lar; shape of the top die member.

17. The method of forming a boilerheader including die-shaping a hollow-blank by the scissors-like action of a pair of side dies,

engagingand pressing the sides of the blank,

the engagement and die shaping beginning at one end of the blank and continuing progressively thereafter to the other end of the blank; a

18. ,An apparatus for formingboiler headers, including a holdingand operating arm pivoted at one end, awork sup'port for supporting a blank, a CllGLfOl shaping one face of theblank mounted insaidarm, and means cally opposed undulations in its sides and a plurality of inclined flat seats in its side.

20. The method of forming a boiler header which comprises subjecting a hollow blank while held on a mandrel in a stationary position to the die shaping action progressively from one end of the blank to the other.

21. The method of forming a boiler top header characterized by exerting pressure on a hollow blank progressively from one end of the blank to the other to bend the walls of the blank into a header of sub stantially rectangular cross section and provided in its lateral sides with diametrically opposed ridges and valleys and on its top side with a plurality of inclined flat seats, the pressure being exerted on substantially the whole length of the blank at the end of the operation.

22. The method of forming a boiler header characterized by arranging a hollow blank over a mandrel having die portions, progressively bending portions in the lateral sides of the blank in engagement with said die portions from one end of the blank to the other so as to form diametrically opposed undulations.

23. The method of forming a boiler header characterized by arranging a hollow blank over a mandrel and thereafter progressively bending portions in the lateral and top sides of the blank inwardly from one end of the blank to the other and forming its lateral sides with diametrically opposed undulations, and on its top side with flat seat faces disposed at an angle to the longitudinal axis of the blank.-

24. In an apparatus for forming boiler headers including a pair of holding and operating arms pivoted at one end, dies for shaping the sides of a blank held between said arms, means for actuatin said arms and dies to engage and shape the sides of the blank progressively from one end to the other.

An apparatus for forming boiler headers including a plurality of holding and operatlng arms pivoted at one end, dies provided in said arms for shaping the sides for applying pressure to the top arm and die so as to engage the top portion of the blank progressively from one end to the other.

26. An apparatus for forming boiler headers including a base, a work support on said base, a pair of holding and operating arms pivoted to said base at one end, dies provided in said arms for shaping the sides of a blank held on the workisupport and means for applying pressure to the arms which is transmitted to a blank from one end to the other to shape the blank into a header.

27. An apparatus for forming boiler headers including a base, a work support on said base, a pair of holding and operating arms pivoted to the said arms for shaping the sides of a blank held on the work support, a top arm pivoted near the same end of said apparatus and provided with a top die, and means for applying pressure to said side arms and said top arm so that the side dies and top die engage the blank be-- ginning at one end and pressure is applied progressively thruout the length of the blank to the other end.

28. The method of forming a boiler header which comprises arranging a hollow blank over a mandrel having die portions, progressively bending portions in the lateral sides of the blank in engagement with the die portions from one end of the blank to the other so as to form diametrically opposed undulations in the lateral sides of the blank while applying pressure on the top side of the blank.

29. The method of forming an article of the character described which comprises ar ranging a hollow blank over a mandrel and thereafter progressively bending portions in the lateral sides of the blank inwardly from one end of the blank to the other while applying pressure on the top and bottom sides of the blank so as to form a header of substantially rectangular shape in cross section and provided in its lateral sides with diametrically opposed undulations and on is top side with flat seat faces disposed a? angle to the longitudinal axis of the 30. The method of forming an article 01' the character described which comprises po sitiomng a hollow blank on a mandrel having die portions, progressively bending por-.

the lateral sides of the blank and flat seatfaces on the top side of the blank.

In testimony that I claim the foregoing I have hereunto set my hand this 6th day of February, 1928. e

JOHN J. CAIN. 

